vespa gts 250 service manual

8/18/2019 Vespa GTS 250 Service Manual

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Vespa would like to thank you

for choosing one of its products. We have prepared this booklet to help you to get the very best from your scooter. Please read it carefully before riding

the scooter for the first time. It contains information, tips and precautions for using your scooter. It also describes features, details and devices to assure

you that you have made the right choice. We believe that if you follow our suggestions, you will soon get to know your new vehicle and it will serve you

well for a long time to come. This booklet forms an integral part of the scooter; should the scooter be sold, it must be transferred to the new owner.

Vespa GTS 250

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The instructions given in this booklet are intended to provide a clear, simple guide to using your scooter; details are also given of routine maintenance

procedures and regular checks that should be carried out on the vehicle at an Author ised PIAGGIO Dealer or Serv ice Centre. The booklet also

contains instructions for simple repairs. Any operations not specifically described in this booklet require the use of special tools and/or particular technicalknowledge: to carry out these operations refer to any authoris ed PIAGGIO Dealer of Service Centre.

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Personal safety

Failure to completely observe these instructions will result in serious risk of personalinjury.

Safeguarding the environment

Sections marked with this symbol indicate the correct use of the vehicle to prevent dam-aging the environment.

Vehicle intactness

The incomplete or non-observance of these regulations leads to the risk of seriousdamage to the vehicle and sometimes even the invalidity of the guarantee.

The signs that you see on this page are very important. They are used to highlight thoseparts of the booklet that should be read with particular care. As you can see, each signconsists of a different graphic symbol, making it quick and easy to locate the varioustopics.

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INDEX

VEHICLE...................................................................................... 7Dashboard................................................................................ 8

Analogue instrument panel....................................................... 8

Clock......................................................................................... 10

Digital lcd display...................................................................... 10Setting the total and trip odometers...................................... 11

Key switch................................................................................. 11

Locking the steering wheel.................................................... 11Releasing the steering wheel................................................ 12Switch direction indicators........................................................ 12

Horn button............................................................................... 13

Light switch............................................................................... 13

Start-up button.......................................................................... 14Engine stop button.................................................................... 14

The immobilizer system............................................................ 14

Keys...................................................................................... 15Immobilizerdevice enabled indicator led............................... 16

Operation............................................................................... 17

Programming the immobilizer system................................... 18

Accessing the fuel tank............................................................. 20Opening the saddle............................................................... 21

Identification.............................................................................. 21

Rear top box opening................................................................ 22

USE.............................................................................................. 25Checks...................................................................................... 26

Refuelling.................................................................................. 26

Tyre pressure............................................................................ 29

Shock absorbers adjustment.................................................... 30Running in................................................................................. 31

Starting up the engine............................................................... 31

Precautions........................................................................... 32Difficult start up......................................................................... 33

Stopping the engine.................................................................. 33

Stand......................................................................................... 34 Automatic transmission............................................................. 34

Safe driving............................................................................... 35

Rear rack.................................................................................. 37

MAINTENANCE........................................................................... 39Engine oil level.......................................................................... 40

Engine oil level check............................................................ 40

Engine oil top-up................................................................... 40Warning light (insufficient oil pressure)................................. 41Engine oil change.................................................................. 41

Hub oil level.............................................................................. 43

Tyres......................................................................................... 45

Spark plug dismantlement........................................................ 46Removing the air filter............................................................... 47

Cooling fluid level...................................................................... 48

Checking the brake oil level...................................................... 50Battery....................................................................................... 51

Use of a new battery............................................................. 52

Long periods of inactivity.......................................................... 53

Fuses........................................................................................ 54Front light group........................................................................ 59

Headlight adjustment............................................................. 61

Front direction indicators........................................................... 61

Rear optical unit........................................................................ 62Rear turn indicators................................................................... 62

Rear-view mirrors...................................................................... 63

Front and rear disc brake.......................................................... 63

Puncture.................................................................................... 64Periods of inactivity................................................................... 65

Cleaning the vehicle.................................................................. 65

TECHNICAL DATA...................................................................... 71Kit equipment............................................................................ 76

SPARE PARTS AND ACCESSORIES........................................ 77

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Warnings................................................................................... 78

PROGRAMMED MAINTENANCE............................................... 81

Scheduled maintenance table................................................... 82

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Vespa GTS

250

Chap. 01Vehicle

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01_01

Dashboard (01_01)

A = Starter buttonB = Engine block Run-Off switch

C = Throttle control

D = Front brake lever

E = Instrument panel

F = Rear brake control lever

G = Horn button

H = Turn indicator switch

I = Light switch

Analogue instrument panel (01_02)

A = Digital dashboard

B = Rhs turn signal indicator light

C = Headlights indicator light

D = Low-oil pressure warning light

E = High-beam indicator lighti

F = Low-fuel warning light

G = Speedometer

H = Lhs turn signal indicator light

I = Antitheft LED (immobilizer)

L = Engine management and injection diagnostics light

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01_02

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01_03

Clock (01_03)

Located on the instrument panel, it displays hours and minutes with 1 to 24 hour time.

Besides hours and minutes, month and day can also be displayed with the «T» button.

In order to adjust the above mentioned functions, operate button «U».

01_04

Digital l cd display (01_04)

A = Odometer

B = Coolant temperature gauge

C = Fuel level gauge

D = Tachometer

E = Digital clock

F = External temperature indicator

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01_05

Setting the total and trip odometers (01_05)

The «TRIP» button displays the total and partial kilometres covered when pressed

repeatedly for less than 1 second. It resets the trip odometer when pushed more than

3 seconds. Push the «TRIP» button again to return to total odometer value.

01_06

Key switch (01_06)

LOCK = ignition disabled, extractable key, mechanical antitheft device enabled.

OFF = ignition disabled, extractable key, mechanical antitheft device disabled.

ON = Ready to ignition position, non-extractable key, mechanical antitheft device dis-

abled, lights on.

Locking the steering wheel

Turn the handlebar to the left (as far as it will go), turn the key to «LOCK» and remove

the key.

CAUTION

DO NOT TURN THE KEY TO «LOCK» OR «OFF» WHILE RIDING.

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Releasing the steering wheel

Reinsert the key and turn it to «OFF».

CAUTION

DO NOT TURN THE KEY TO «LOCK» OR «OFF» WHILE RIDING.

01_07

Switch direction indicators (01_07)

Lever towards "S" = Left turn indicator is switched on;

Lever towards "D" = Right turn indicator is switched on;

The lever returns automatically to position "0" and the turn indicator "B" remains on;

press the lever to turn them off.

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01_10

Start-up button (01_10)

Starter button "G"

01_11

Engine stop but ton (01_11)

0 = OFF

1 = RUN

The immobilizer systemIn order to enhance theft protection, the scooter is equipped with a «PIAGGIO IM-

MOBILIZER » electronic engine locking device that is activated automatically when

the starter key is removed. Upon start-up, the «PIAGGIO IMMOBILIZER» systemchecks the starter key, and only if this key is recognised will the immobilizer system

allow the scooter to be started.

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01_12

01_13

01_14

Keys (01_12, 01_13, 01_14)

Two types of keys come with the vehicle.

The red-handgrip key " A" is the "MASTER" key.

Only a single copy of this key is supplied, which is necessary to program all your other keys and for your dealer to perform some maintenance operations. For this reason it

is advised that it be used only in exceptional circumstances.

The blue key «B» (single copy supplied) is used for normal operations such as:

- engine start up

- glove-box opening

Together with the two keys, you wil l be given a CODE CARD bearing the same codeimprinted onto the two keys.

WARNING

LOSING THE RED KEY PREVENTS ANY REPAIRS OF THE 'PIAGGIO IMMOBIL-

IZER' SYSTEM AND THE ENGINE CONTROL UNIT.

WARNING

KEEP THE 'CODE CARD' AND THE RED HANDGRIP KEY IN A SAFE PLACE (NOT

ON YOUR VEHICLE).

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Immobil izerdevice enabled indicator led (01_15)

The operation of the «PIAGGIO IMMOBILIZER» system is signalled by a blinking

indicator light, «I» (see the «Analogue dashboard» section).

To prevent the battery from discharging, the indicator led automatically shuts down

after 48 hours of uninterrupted operation.

In the event of a malfunction to the system, the indicator led provides diagnostic in-

formation to your Aut horised Piaggio Service Centre through its blinking patterns.

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01_15

Operation

Every time the starter key is removed in the "OFF" or "LOCK" position, the safety

system activates the immobilizer system. Turning the key to "ON" disables the enginelock, provided that the safety system recognises the code transmitted by the key. If

the code is not recognised, turn the key first to " OFF" and then to "ON"; if the lock

cannot be disabled, try with the other key supplied (red-coloured). If the engine cannot

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be started, contact an Aut horised Piaggio Service Cent re, which is provided with

the electronic equipment required to detect and repair the system.

When additional keys are required, please note that data storage (up to 7 keys max.)

must be done on all keys, both new ones and existing ones.

Take your scooter to an Author ised Pi aggi o Service Cent re carrying with you the

red-handgrip key and all the blue keys in your possession.

The codes of keys not submitted for the new storage procedure are deleted from the

memory. Any lost keys will therefore not be enabled to start the engine.

WARNING

EACH KEY HAS ITS OWN AND UNIQUE CODE, WHICH MUST BE STORED BY

THE SYSTEM CONTROL UNIT.

VIOLENT SHOCKS MAY AFFECT THE ELECTRONIC COMPONENTS OF THE

KEY.

IF OWNERSHIP OF THE VEHICLE IS TRANSFERRED, THE RED-HANDGRIP KEY

(AS WELL AS THE OTHER KEYS) AND THE "CODE CARD" MUST ALSO BE

TRANSFERRED TO THE NEW OWNER.

Programming the immobilizer system

Below is described the procedure to follow for programming the PIAGGIO IMMOBIL-

IZER system and/or for storing other key codes. The programming procedure shouldbe carried out with the engine stop switch set to «RUN».

Procedure start - red key

Insert the red-handgrip key in the switch key (in "OFF" position) and turn it to "ON".

After 1 - 3 seconds, turn the key to "OFF" again and pull it out.

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Intermediate step - blu key

Within ten seconds after pulling out the red key, insert the black key and promptly turnit to «ON». After 1-3 seconds, turn the key to "OFF" again and pull it out.

In this way, a maximum of 3 blue keys can be programmed by repeating the aboveprocedure and keeping the indicated times.

Final step - red key

After pulling out the last blue key, insert the red key again and turn it to "ON" (this

operation should be performed within 10 seconds of pulling out the previous key).Leave it in this position for 1 to 3 seconds and return it to the «OFF» position.

Proper programming check

Insert the red key disabling the transponder (i.e., tilt the key cap by 90°) and turn the

key to "ON". Perform the engine start-up operation. Ensure that the engine does not

start. Insert the blue key and repeat the start-up operation. Check that engine starts.

WARNING

SHOULD THE ENGINE START WITH THE RED KEY (WITH TRA NSPONDER OFF),

OR IN THE EVENT OF WRONG OPERATION DURING PROGRAMMING, REPEAT

THE PROCEDURE FROM THE BEGINNING.

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01_16

01_17

01_18

Accessing the fuel tank (01_16, 01_17, 01_18)

With the key set to «OFF» or «ON», or with engine on, it is possible to electrically open

the saddle by pressing the button «C». If the saddle opening system does not work,

operate the emergency lever « A». Then, unscrew cap «B» and the fuel tank can bereached.

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01_19

01_20

Opening the saddle (01_19, 01_20)

With the key set to «OFF» or «ON», or with engine on, it is possible to electrically open

the saddle by pressing button «C». If the electric opening does not work, use the

emergency lever " A". When the key is set to «LOCK» the saddle cannot be opened.

01_21

Identi fication (01_21, 01_22, 01_23)

The identification registration numbers consist of a prefix followed by a number stam-ped on both the chassis « A» and the engine «B». These numbers must always be

indicated on spare parts requests. To read the chassis number, lift the saddle and

remove the helmet compartment «C». We recommend checking that the chassis reg-

istration number stamped on the vehicle corresponds with that on the vehicle docu-mentation.

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01_22

01_23

CAUTION

BE REMINDED THAT ALTERING IDENTIFICATION REGISTRATION NUMBERSCAN LEAD TO SERIOUS PENAL SANCTIONS (IMPOUNDING OF THE VEHICLE,

ETC.).

01_24

Rear top box opening (01_24)

Insert the key into the switch and press down until the glove compartment opens. If the switch is set to "LOCK", turn the key to "OFF" or "ON" before pressing it down.

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Vespa GTS

250

Chap. 02Use

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Checks

Before using the vehicle, check:

1. There is enough fuel in the fuel tank.

2. The correct fluid level for front and rear brakes.

3. That tyres are properly inflated.

4. The correct functioning of tail lights, headlamp, turn indicators, stop light and license

plate light.

5. The correct functioning of front and rear brakes.

6. The oil level in the gearcase.

7. The engine oil level.

8. The coolant level.

02_01

Refuell ing (02_01, 02_02)

Fuel: lift the seat and remove the filler cap «B». Recommended fuel: Unleaded petrol;

95 octane min. The low-fuel warning light «F» goes on when the fuel level reaches

the reserve mark.

WARNING

SWITCH OFF THE ENGINE BEFORE REFUELLING WITH PETROL.

PETROL IS HIGHLY INFLAMMABLE.

DO NOT SMOKE AND KEEP OPEN FLAMES AT A DISTANCE:FIRE HAZARD.

DO NOT INHALE FUEL FUMES.

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DO NOT ALLOW PETROL TO COME INTO CONTACT WITH HOT ENGINE OR ANY PLASTIC PARTS.

CAUTION

PETROL DAMAGES THE PLASTIC PARTS OF THE BODYWORK.

CAUTION

USING OILS OTHER THAN THOSE RECOMMENDED CAN SHORTEN THE LIFEOF THE ENGINE.

CAUTION

DO NOT USE THE VEHICLE TO THE COMPLETE EXHAUSTION OF THE FUEL;

IN THE EVENT THAT THIS SHOULD OCCUR, DO NOT ATTEMPT TO START THEENGINE. TURN THE KEY SWITCH TO OFF AND TOP-UP THE TANK AS SOON

AS POSSIBLE. FAILURE TO FOLLOW THESE GUIDELINES COULD DA MAGE

THE FUEL PUMP AND/OR THE CATALYTIC CONVERTER.

Characteristic

Fuel tank capacity

~ 9.2 litres

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02_02

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02_03

Tyre pressure (02_03)

Check the tyre pressure and wear periodically (roughly every 500 km). The tyres are

equipped with wear indicators; the tyres should be replaced as soon as these indica-

tors become visible on the tyre tread. Also check that tyres do not show cuts on thesides or irregular tread wear; if this occurs, go to an authorised workshop or at least

a workshop equipped to perform the replacement.

CAUTION

TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD.INCOR-

RECT TYRE PRESSURE CAUSES ABNORMAL TYRE WEAR AND MAKES RID-ING DANGEROUS.

TYRES MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR LIMITS

SET FORTH BY LAW.

Characteristic

Front tyre pressure

1.8 bar

Rear tyre pressure

2 bar

Rear tyre pressure - driver and passenger

2.2 bar

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02_04

Shock absorbers adjustment (02_04)

The preloading of the springs can be adjusted to 4 positions using the ring nut located

in the lower part of the shock absorbers and the specific spanner supplied.

Position 1: minimum preload: driver only

Position 2 medium preloading: driver only

Position 3 medium preloading: rider and passenger

Position 4: maximum preloading: driver, passenger, and luggage.

In order to carry out this operation you will need to use the specific spanner in the kit.

CAUTION

RIDING THE VEHICLE WITH THE SPRING PRELOADING NOT CORRECTLY SET

FOR THE RIDER AND POSSIBLE PASSENGER, COULD REDUCE THE COM-

FORT OF THE RIDE AND THE PRECISION OF THE STEERING.

WARNING

WE RECOMMEND WEARING GLOVES WHILE CARRYING OUT THIS OPERA-

TION IN ORDER TO AVOID INJURIES.

WARNING

WE STRONGLY RECOMMEND NOT TO ADJUST BOTH SHOCK ABSORBERS

WITH DIFFERENT PRELOADING

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02_05

Running in (02_05)

WARNING

DURING THE FIRST 1000 KM DO NOT RIDE THE VEHICLE OVER 80% OF ITSMAXIMUM SPEED. AVOID TWISTING THE THROTTLE GRIP FULLY OR KEEP-

ING A CONSTANT SPEED ALONG LONG SECTIONS OF ROAD. AFTER THE

FIRST 1000 KM, GRADUALLY INCREASE SPEED UNTIL REACHING THE MAX-IMUM PERFORMANCE.

02_06

Starting up the engine (02_06, 02_07)

To start the engine it is necessary, before pressing the starter button, to pull and keep

pulled the front or rear brake lever, which activates the appropriate switch allowingstart-up.

1. Rest the vehicle on its centre-stand, ensuring the rear wheel is not touching the

ground.

2. Maintain the throttle grip «E» completely untwisted.

3. Insert the key into the ignition switch « A» and turn to position «ON».

4. Make sure that switch «B» "0-1" is set to "1".

5. Pull lever «C» of the front or rear brake and then activate the starter button «D».

WARNING

THE AUTOMATIC TRANSMISSION MAKES THE REAR WHEEL TURN EVENWHEN THE THROTTLE IS SLIGHTLY TWISTED. RELEASE THE BRAKE CARE-

FULLY AFTER STARTING, AND THEN ACCELERATE GRADUALLY.

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02_07

CAUTION

DO NOT START-UP THE ENGINE IN CLOSED AREAS BECAUSE EXHAUSTGASES ARE TOXIC.

Precautions

CAUTION

NEVER STRESS THE ENGINE AT LOW TEMPERATURES IN ORDER TO AVOID

POSSIBLE DAMAGE. BE CAREFUL NEVER TO EXCEED THE MAXIMUM SPEED

WHILE RUNNING DOWNHILL, IN ORDER TO AVOID DAMAGING THE ENGINE.IN ANY CASE, IN ORDER TO PRESERVE THE ENGINE FROM PROLONGED EX-

CESSIVE REVOLUTIONS, THE REVOLUTION LIMITER WILL BE ACTIVATED IF

THE ENGINE SPEED EXCEEDS THE ESTABLISHED THRESHOLD.

WARNING

AFTER A LONG DISTANCE COVERED AT THE MAXIMUM SPEED, DO NOT STOP

THE ENGINE IMMEDIATELY, BUT LET IT RUN AT IDLE FOR A FEW SECONDS.

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Difficult start up

In the rare case of flooding the engine, to facilitate start-up, it is possible to try to put

the vehicle into action with the gas hand grip partially or completely open. It is however

necessary, once the engine is started, to take your vehicle to an Author ised ServiceCentre to determine the cause of this problem and to re-establish the vehicle proper

functioning.

02_08

02_09

Stopping the engine (02_08, 02_09)

Fully untwist the throttle grip and then turn the switch key « A» to «OFF» (extractable

key), or turn the switch «B» to «0».

CAUTION

DUE TO THE HIGH TEMPERATURES THE CATALYTIC CONVERTER CANREACH, ALWAYS TAKE CARE, WHEN PARKING THE SCOOTER, THAT THE

EXHAUST DOES NOT COME INTO CONTACT WITH FLAMMABLE MATERIALS,

TO AVOID SERIOUS BURNS.

CAUTION

DO NOT SWITCH OFF THE ENGINE WHILE THE VEHICLE IS MOVING. UN-BURNED FUEL COULD ENTER THE CATALYTIC CONVERTER AND BURN,

CAUSING IT TO OVERHEAT AND POSSIBLY DESTROYING IT.

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Stand (02_10)

CENTRE STAND

Push with your foot on the centre stand's fork «F» while lifting the vehicle backward,

holding onto the handlebar.

02_10

SIDE STAND

With your foot push the projection of the stand «L » in order to open it and at the same

time lean the vehicle on you.

02_11

Automatic transmission (02_11, 02_12)

To ensure simple, pleasurable riding, the vehicle is equipped with automatic trans-mission with regulator and centrifugal clutch. The system is designed to provide the

best performance (acceleration and consumption) while riding on both flat roads and

uphill.

If you have to stop on an uphill slope (traffic l ights, traffic jam, etc.) use only the brake

to keep the vehicle still, leaving the engine running at idle speed. Using theengine to keep the vehicle still can cause the clutch to overheat, due to the

friction of the clutch mechanism itself against the clutch bell.

It is therefore recommended to avoid conditions of prolonged clutch slippage (other

than those previously indicated) like driving uphill fully laden on steep slopes or starting

off with driver and passenger at slopes with steepness greater than 25%.

Observe the following precautions if the clutch overheats:

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02_12

1. Do not continue riding in such conditions.

2. Let the clutch cool down with the engine at idle speed for a few minutes.

Safe driving (02_13, 02_14)

WARNING

SOME SIMPLE TIPS ARE PROVIDED BELOW THAT WILL ENABLE YOU TO USEYOUR SCOOTER ON A DAILY BASIS IN GREATER SAFETY AND WITH MORE

PEACE OF MIND.

<

02_13

Your ability and your knowledge of the vehicle form the basis of safe riding. We rec-

ommend trying out the vehicle in traffic-free zones to get to know your vehiclecompletely.

ALWAYS DRIVE WITHIN YOUR LIMITS

1. Before riding off, remember to put on your helmet and fasten it correctly.

2. Reduce speed and ride cautiously on uneven roads.

3. Remember that after riding on a long stretch of wet road without using the brakes,the braking effect is initially lower. Given these conditions, it is a good idea to operate

the brakes from time to time.

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02_14

4. Do not brake hard on a wet surface, on dirt tracks or on any slippery road surface.

5. If you have to brake, use both brakes in order to divide the braking action between

both wheels.

6. Avoid starting off by mounting the scooter while it is still resting on its stand. In any

case, the rear wheel should not be turning when in comes into contact with the ground,

in order to avoid abrupt departures.

7. If the vehicle is used on roads covered with sand, mud, snow mixed with salt, etc.,

clean the brake disc frequently with mild detergent in order to prevent abrasive sub-

stances from building up within the holes, which can result in early wear of the brakepads.

8. Any elaboration that modifies the vehicle's performances, such as tampering with

original structural parts is strictly forbidden by law, and renders the vehicle not con-forming to the approved type and therefor dangerous to ride.

CAUTION

DO NOT FORGET THAT DRIVING IN A STATE OF DRUNKENNESS, OR WHENUNDER THE EFFECT OF DRUGS OR CERTAIN MEDICINES, CAN BE EXTREME-

LY DANGEROUS FOR ONESELF AND FOR OTHERS.

CAUTION

ANY CHANGES TO THE VEHICLE PERFORMANCE AS WELL AS ALTERATIONSTO ORIGINAL STRUCTURAL PARTS IS STRICTLY FORBIDDEN BY LAW, AND

RENDERS THE VEHICLE NO LONGER CONFORMING TO THE APPROVED TYPE

AND DANGEROUS FOR RIDING.

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02_15

Rear rack (02_15)

When riding without packages on the luggage racks, set the corresponding retainer

latch " A" as shown in the photograph.

WARNING

Maximum admissible load: 6 kg

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Vespa GTS

250

Chap. 03Maintenance

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Engine oil level

In 4T engines, engine oil is used to lubricate the distribution elements, main bearingsand thermal group. An insuff ic ient quant ity of oi l can cause ser ious damage to

the engine itself. In all four-stroke engines, a loss of efficiency in oil performance and

consumption should be considered normal. Consumption can particularly reflect the

conditions of use (i.e. when driving at "full acceleration" all the time, oil consumptionincreases). The replacement frequencies provided for by the maintenance programme

are defined, depending on the total contents of oil in the engine and average con-

sumption measured following standardised methods. In order to prevent any prob-lems, we recommend checking oi l level more frequently than indicated in the

Scheduled Maintenance table or before setting off on long journeys . The vehicle

is, however, equipped with an oil pressure warning light on the ins trument pan-

el.

03_01

Engine oi l level check (03_01)

Every time the scooter is used, a visual check should be made on the level of theengine oil when the engine is cold. The oil level should be somewhere between the

MAX and MIN index marks on the level bar; the check must be made with the scooter

upright, resting on the centre stand. If the check is carried out after the vehicle hasbeen used, and therefore with a hot engine, the level line will be lower; in order to carry

out a correct check, wait at least 10 minutes after the engine has been stopped so as

to get the correct level.

Engine oil top-up

Any topping up with oil must be carried out after the oil level check by adding oil, but

never exceeding the MAX level . The topping up of the level between MIN and

MAX requires approx. 200 cc of oil. Every 5000 km, however, the engine oil levelshould be checked and topped up, if necessary, at an Authorised Piaggio Service

Centre.

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Warning light (insuf ficient oil pressure)

The vehicle is equipped with a warning light that lights up when the key is turned tothe «ON». However, this light should switch off once the engine has been started. If

the light comes on while braking, at idle speed or whi le turning a corner, it is

necessary to check the oil level and top it up if required. If after having topped-

up the oil, the warning light still comes on while braking, at idle speed or whileturning a corner, it will be necessary to take your vehicle to an Authorised Serv-

ice Centre.

03_02

03_03

Engine oil change (03_02, 03_03)

The oil and cartridge filter "C" must be changed after 1,000 km and every 10,000 km

at an authorised Piaggio service centre. The engine should be emptied by drainingthe oil from the drainage cap "B" of the gauze filter on the flywheel side. In order to

facilitate the oil drainage, loosen the cap/dipstick. Since a certain quantity of oil re-

mains in the circuit still, the top-up should be carried out with around 600 ÷ 650 cc of

oil from cap " A". Then start up the scooter, leave it running for a few minutes andswitch it off: after five minutes, check the level and if necessary top up without ex-

ceeding the MAX. level. The cartridge filter must be replaced at every oil change.

For top up and change, use new oil of the recommended type.

WARNING

RUNNING THE ENGINE WITH INSUFFICIENT LUBRICATION OR WITH INADE-QUATE LUBRICANTS ACCELERATES THE WEAR AND TEAR OF THE MOVING

PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE.

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WARNING

EXCESSIVE OIL LEVEL AT TOP-UPS CAN LEAD TO SCALE FORMATION ANDVEHICLE MALFUNCTION.

CAUTION

USED OILS CONTAIN SUBSTANCES HARMFUL TO THE ENVIRONMENT. FOR

OIL CHANGE, CONTACT AN AUTHORISED PIAGGIO SERVICE CENTRE, ASTHEY ARE EQUIPPED TO DISPOSE OF USED OILS IN AN ENVIRONMENTALLY

FRIENDLY AND LEGAL WAY.

CAUTION

USING OILS OTHER THAN THOSE RECOMMENDED CAN SHORTEN THE LIFE

OF THE ENGINE.

Recommended products

AGIP CITY HI TEC 4T

Engine oil

SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil

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03_04

03_05

Hub o il level (03_04, 03_05)

Check the oil in the rear hub. To check the rear hub oil level, proceed as follows:

1) Park the scooter on level ground and rest it on its stand.

2) Unscrew dipstick « A», wipe it clean with a cloth, reinsert it and tighten completely.

3) Pull out the dipstick and check that the oil level is above the first notch from thebottom.

4) Reinsert the dipstick and ensure that it is tightened correctly.

N.B.

THE NOTCHES ON THE HUB OIL LEVEL DIPSTICK, EXCEPT THE ONE INDI-

CATING THE MAX LEVEL, REFER TO OTHER MODELS BY THE MANUFACTUR-ER AND HAVE NO SPECIFIC FUNCTION FOR THIS MODEL.

CAUTION

RIDING THE VEHICLE WITH INSUFFICIENT HUB LUBRICATION OR WITH CON-

TAMINATED OR IMPROPER LUBRICANTS ACCELERATES THE WEAR AND

TEAR OF THE MOVING PARTS AND CAN CAUSE SERIOUS DAMAGE.

CAUTION

USED OIL CAN HARM THE ENVIRONMENT. COLLECTION AND DISPOSALSHOULD BE CARRIED OUT IN COMPLIANCE WITH CURRENT REGULATIONS.

CAUTION

AN EXCESSIVE QUANTITY OF OIL CAN LEAD TO SPILL OVER, WHICH MAY

CAUSE THE ENGINE AND THE WHEEL TO GET DIRTY.

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CAUTION

WHEN REPLACING THE HUB OIL DO NOT LET THE OIL COME INTO CONTACTWITH THE REAR BRAKE DISC.

CAUTION

FOR OIL REPLACEMENT, CONTACT ANY AUTHORISED SERVICE CENTRE AS

THEY ARE EQUIPPED TO DISPOSE OF USED OILS IN AN ENVIRONMENTALLYFRIENDLY AND LEGAL WAY.


AGIP ROTRA 80W-90

Rear hub oil

SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications

Characteristic

Rear hub o il

250 cc

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03_06

Tyres (03_06)

Check tyre pressure periodically (about every 500 km). Tyres feature wear indicators;

replace tyres as soon as these indicators become visible on the tyre tread. Also check

that the tyres do not show signs of splitting at the side or irregular tread wear; if thisoccurs, go to an authorised workshop or at least to a workshop equipped to perform

the replacement.

CAUTION

TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD.INCOR-

RECT TYRE PRESSURE CAUSES ABNORMAL TYRE WEAR AND MAKES RID-ING DANGEROUS.

TYRES MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR LIMITS

SET FORTH BY LAW.

Characteristic

Front tyre pressure

1.8 bar

Rear tyre pressure

2 bar

Rear tyre pressure - driver and passenger

2.2 bar

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03_07

03_08

Spark plug dismantlement (03_07, 03_08)

Proceed as follows:

1. lift the saddle « A»

2. lift the helmet compartment «B» and reach into the spark plug with your hand;

3. disconnect cap of the spark plug HV wire;

4. unscrew the spark plug using the spark plug spanners «D» supplied;

5. When refitting, place the spark plug in the hole at the due inclination and screw it

by hand until it is finger tight;

6. use the box-spanner«D» supplied only for locking;

7. place cap fully over the spark plug.

WARNING

THE SPARK PLUG MUST BE REMOVED WHEN THE ENGINE IS COLD. THE

SPARK PLUG MUST BE REPLACED EVERY 20,000 KM. USE OF ELECTRONICCONTROL UNITS OR ELECTRONIC IGNITIONS DIFFERING FROM THOSE REC-

OMMENDED CAN SERIOUSLY DAMAGE THE ENGINE.

CAUTION

THE USE OF SPARK PLUGS OTHER THAN THOSE RECOMMENDED OR ASHIELDLESS SPARK PLUG CAP COULD CAUSE DISTURBANCES TO THE SYS-

TEM.

Characteristic

Recommended spark plug

Champion RG 4 PHP

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03_09

03_10

03_11

Removing the air fi lter (03_09, 03_10, 03_11, 03_12)

Proceed as follows:

1. unscrew the fixing screw « A».

2. unscrew the nut «B» under the body.

3. remove the left side fairing.

4. remove the helmet compartment;

5. unscrew the fixing screws «C» that can be reached once the helmet compartment

has been removed;

6. Unscrew the screws «D» and remove the air filter cover.

Remove the filtering element and clean it with water and shampoo; then dry it with a

clean cloth and short blasts of compressed air. Finally, immerse it in a mixture of 50%

oil of the recommended type and 50% petrol. Then gently squeeze the filter elementbetween your hands, allow it to drip and then refit it. Oil or water deposits in the filter

housing can be cleaned off by removing the two rubber caps «E».

CAUTION

IF THE VEHICLE IS USED ON DUSTY ROADS, IT IS NECESSARY TO SERVICETHE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.

CAUTION

IN ORDER NOT TO DAMAGE THE VEHICLE PLASTIC COVERS CONTACT AN

AUTHORISED SERVICE CENTRE TO HAVE THE AIR FILTER CLEANED.


AGIP FILTER OIL

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03_12

Oil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

03_13

03_14

Cooling fluid level (03_13, 03_14)

Engine cooling is carried out by a forced-circulation coolant system; the cooling system

holds about 2.100 ÷ 2.150 l of coolant- a mixture of 50% de-ionised water and 50%

ethylene-glycol antifreeze solution and corrosion inhibitors. Recommended coolant,supplied with already mixed and ready for use fluid. For proper functioning of the en-

gine, the coolant temperature needle should be within the middle zone of the scale

between the 5th and 8th bar. If the needle points at the 10th bar, the instrument bars

lit at that moment start flashing. Stop the engine, let it cool down and check the fluidlevel; if the level is OK, take your scooter to an Authorised Piaggio Service Cen-

tre. If when using your scooter at a low gear the coolant temperature exceeds the

above values, shut off the engine and let it cool down. Then check the coolant level.if level is OK, take your scooter to an Author ised Piaggio Serv ice Centre. The fluid

level must checked every 10,000 kilometres with a cold engine, in the way shown

below:

a) Place the scooter in a vertical position on the stand.

b) Unscrew the fixing screw « A» and remove the cover.

c) Check the fluid level according to the two marks- MIN and MAX «B» on the reservoir

d) Top up, if necessary, if the fluid level is below the MIN level on the scale inside theexpansion tank. The fluid level must always be between MIN and MAX level

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If the fluid is near the minimum level, top-up only when the engine is cold. If it is nec-

essary to top up the coolant frequently, or if the expansion tank is completely dry, you

should look for the cause in the cooling system. Have the cooling system checked atan Aut horised Piaggio Service Centre. Coolant must be changed every 2 years at

an Author ised Piaggi o Service Centre.

WARNING

TO AVOID THE RISK OF SCALDING, DO NOT UNSCREW THE EXPANSION

TANK COVER WHILE THE ENGINE IS STILL HOT.

WARNING

IN ORDER TO AVOID HARMFUL FLUID LEAKS WHILE RIDING, IT IS IMPORTANT

TO MAKE SURE THAT THE LEVEL NEVER EXCEEDS THE MAXIMUM VALUE.

IN ORDER TO GUARANTEE THE PROPER FUNCTION OF THE ENGINE, IT IS

NECESSARY TO KEEP THE RADIATOR GRILLE CLEAN.


AGIP PERMANENT SPEZIAL

coolant

Monoethylene glycol-based antifreeze fluid, CUNA NC 956-16

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03_15

03_16

Checking the brake oil level (03_15, 03_16)

The brake reservoirs are located on top of the pumps, underneath the handlebar cover

(front on the rhs and rear on the left). The procedures for the inspection of the brake

fluid level for the front and rear brakes are identical.

Proceed as follows:

1. rest the vehicle on its centre-stand with the handlebars perfectly horizontal;

2. loosen screw « A» and remove cover «B»;

3. remove both riding mirrors;

4. check the brake fluid level through the sight hole, «C».

The brake fluid level inside the reservoirs will decrease as the brake pads start wearingout. Should the level appear to be below the minimum mark, please contact your nearest in order to carry out a thorough inspection of the braking system. Proceed as

follows:

remove the reservoir cap, «D», by loosening the two screws, «E»; hence top-up using

the recommended fluid only, and without exceeding the max mark.

Under normal weather conditions, the brake fluid must be replaced every 2 years. This

operation must be carried out by trained personnel; it is therefore necessary to contact

an Author ised PIAGGIO Service Station

WARNING

ONLY USE DOT 4 CLASS BRAKE FLUIDS. COOLING SYSTEM FLUIDS AREHIGHLY CORROSIVE. MAKE SURE THAT IT DOES NOT COME INTO CONTACT

WITH THE PAINTWORK

.

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CAUTION

AVOID CONTACT OF BRAKE FLUID WITH EYES, SKIN, AND CLOTHING. INCASE OF CONTACT, RINSE WITH WATER. THE BRAKING CIRCUIT FLUID IS

HYGROSCOPIC, THAT IS, IT ABSORBS HUMIDITY FROM THE SURROUNDING

AIR. IF THE HUMIDITY IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE,

IT WILL LEAD TO INEFFICIENT BRAKING. NEVER USE BRAKING FLUID KEPTIN CONTAINERS THAT HAVE ALREADY BEEN OPENED, OR PARTIALLY USED.


AGIP BRA KE 4Brake fluid

FMVSS DOT 4 Synthetic fluid

03_17

Battery (03_17, 03_18, 03_19)

To reach the battery D, proceed as follows:

1. rest the scooter on its centre stand;

2. unscrew the 4 screws « A», remove the footrest «B».

3. remove the two battery fixing screws «C».

The battery is the electrical device that requires the most frequent inspections anddiligent maintenance. The main points of maintenance to be observed are as follows:

CAUTION

IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYSTEM, NEVER DISCON-

NECT THE WIRING WHILE THE ENGINE IS RUNNING. DO NOT TIP THE SCOOT-

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03_18

03_19

ER TOO MUCH IN ORDER TO AVOID DANGEROUS LEAKAGE OF BATTERYELECTROLYTE

.

CAUTION

ELECTROLYTE CONTAINS SULPHURIC ACID: AVOID CONTACT WITH EYES,

SKIN AND CLOTHES. IN THE CASE OF ACCIDENTAL CONTACT, RINSE WITH

ABUNDANT OF WATER AND CONSULT A DOCTOR.

WARNING

SPENT BATTERIES ARE HARMFUL FOR THE ENVIRONMENT. COLLECTION

AND DISPOSAL SHOULD BE CARRIED OUT IN COMPLIANCE WITH CURRENT

REGULATIONS.

Electric characteristi c

Battery

12V - 12 Ah

Use of a new batteryEnsure that the terminals are connected correctly and check voltage.

CAUTION

DO NOT REVERSE THE POLARITY: RISK OF SHORT CIRCUIT AND DAMAGE

TO THE ELECTRICAL SYSTEM.

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WARNING

SPENT BATTERIES ARE HARMFUL FOR THE ENVIRONMENT. COLLECTION AND DISPOSAL SHOULD BE CARRIED OUT IN COMPLIANCE WITH CURRENT

REGULATIONS.

Long periods of inactivity

Battery performance will decrease if the vehicle is not used for a long time. This is theresult of the natural phenomenon of battery discharging plus residual absorption by

vehicle components with constant power consumption. Poor battery performance may

also be due to environmental conditions and the cleanness of the poles. In order toavoid difficult starts and/or irreversible damage to the battery, follow any of these

steps:

- At least once a month start the engine and run it slightly above idle speed for 10-15

minutes. This keeps all the engine components, as well as the battery, in good working

order.

- Take your vehicle to a garage (as indicated in the "Vehicle not used for extended

periods" section) to have the battery removed. Have the battery cleaned, charged fullyand stored in a dry, ventilated place. Recharge at least once every two months .

N.B.

THE BATTERY MUST BE CHARGED WITH A CURRENT EQUAL TO 1/10 OF THERATED CAPACITY OF THE BATTERY AND FOR NOT LONGER THAN 10 HOURS.CONTACT AN AUTHORISED SERVICE CENTRE TO CARRY OUT THIS OPERA-

TION SAFELY. WHEN REFITTING THE BATTERY MAKE SURE THE LEADS ARE

CORRECTLY CONNECTED TO THE TERMINALS.

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WARNING

DO NOT DISCONNECT THE BATTERY CABLES WITH THE ENGINE RUNNING,THIS CAN CAUSE PERMANENT DAMAGE TO THE VEHICLE ELECTRONIC CON-

TROL UNIT.

WARNING

SPENT BATTERIES ARE HARMFUL FOR THE ENVIRONMENT. COLLECTION AND DISPOSAL SHOULD BE CARRIED OUT IN COMPLIANCE WITH CURRENT

REGULATIONS.

Fuses (03_20, 03_21, 03_22, 03_23, 03_24, 03_25)

The electrical system is equipped with:

1. six protection fuses « A» located in the glove compartment to the left

2. two fuses «B» located under the helmet compartment under the saddle hinge latch.

3. two fuses «C» located under the helmet compartment on the side fairing.

The chart shows the position and characteristics of the fuses in the vehicle.

CAUTION

BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT

CAUSED IT TO BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANY OTHERMATERIAL (E.G., A PIECE OF ELECTRIC WIRE).

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CAUTION

MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYSTEM, PERFORMEDINCORRECTLY OR WITHOUT STRICT ATTENTION TO THE TECHNICAL SPEC-

IFICATIONS OF THE SYSTEM, CAN CAUSE ERRORS IN FUNCTIONING AND

RISK OF FIRE.

FUSES

General Position on fuse box: 1

Fuse: 30A

Protected circui ts: General

Ignition ECU Fuse box arrangement: 2

Fuse capacity: 7,5 A

Protected circui ts: Ignition ECU

Injection loads relay Fuse box arrangement: 3

Fuse capacity: 10 A

Protected circuit s: Injection loads

relay

Injection ECU Fuse box arrangement: 4


Protected circui ts: Injection ECU

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Dashboard lighting, intercom and

anti-theft device pre-wiring

Fuse box arrangement: 5

Fuse capacity: 10 A

Protected circuits: Dashboard

lighting, intercom and anti-theft

device pre-wiring

High and low-beam lights, horn Fuse box arrangement: 6


Protected circuit s: High and low-beam lights, horn

High and low-beam lights, electricseat opening


Fuse capacity: 15 A

Protected circuit s: High and low-

beam lights, electric seat opening

Dashboard Fuel supply, intercom

and anti-theft device pre-wiring


Fuse capacity: 10 A

Protected circuits: DashboardFuel supply, intercom and anti-

theft device pre-wiring

Starter motor, stop light Fuse box arrangement: 9Fuse capacity: 7,5 A

Protected circuit s: Starter motor,

stop light

Front and rear side lights,

dashboard lighting



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Protected circuit s: Front and rear

side lights, dashboard lighting

03_20

03_21

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03_22

03_23

03_24

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03_25

03_26

03_27

Front light group (03_26, 03_27, 03_28, 03_29, 03_30)

To remove the headlight assembly, proceed as follows:

1: remove the riding mirrors.

2: remove screw « A» from the front grille.

3: remove the front handlebar cover fixing screw, «B».

4: remove the rear handlebar cover fixing screw, «C».

5: Detach the front handlebar cover.

This provides access to the light bulbs. Turn the ring nut and extract the high/low-

beam light bulb, «D». To replace the side light bulb, extract the rubber socket from

within its housing. Upon refitting, repeat these operations backwards.

WARNING

THE TWIN-FILAMENT (HIGH-BEAM AND LOW-BEAM) BULB IS HALOGEN: DO

NOT TOUCH THE BULB WITH YOUR FINGERS TO AVOID COMPROMISING ITS

FUNCTIONING

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03_28

03_29

N.B.

IF MISTING IS NOTICED ON THE INSIDE OF THE HEADLAMP GLASS, THIS

DOES NOT INDICATE A FAULT AND IS RELATED TO THE HUMIDITY AND/OR

TO LOW TEMPERATURES.

THE PHENOMENON SHOULD QUICKLY DISAPPEAR WHEN THE LIGHT IS

SWITCHED ON.

THE PRESENCE OF DROPS OF WATER, ON THE OTHER HAND, COULD INDI-

CATE THAT WATER IS INFILTRATING. CONTACT THE PIAGGIO AFTER-SALES

SERVICE NETWORK.

Electric characteristi c

Bulbs

1 bulb, 12V/55-60W, for high- and low-beam lights

2 bulbs, 12V/5W, for taillights

03_30

To remove the tail light on the shield, proceed as follows:

1: Remove the screw « A» of the front shield grille.

2: Rotate the front shield grille.

To replace the tail light, pull out the rubber lamp holder from its fitting. To reassemble,

repeat the operation in the reverse order.

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03_31

03_32

Headlight adjustment (03_31, 03_32)

Proceed as follows:

1. Place the vehicle in running order and with the tyres inflated to the prescribed pres-

sure, on a flat surface 10 m away from a white screen situated in a shaded area,

making sure that the longitudinal axis of the scooter is perpendicular to the screen;

2. Turn on the headlight and check that the borderline of the projected light beam on

the screen is not lower than 9/10 of the distance from the ground to the centre of vehicle headlamp and higher than 7/10;

3. If otherwise, adjust the right headlight with screw « A».

N.B.

THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS RE-

GARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE

STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE ve-hicle IS USED.

03_33

Front di rection indicators (03_33)

To replace the front turn indicator bulbs, remove the tail light taking out the retainingscrew "A", remove the bulb holder from its fitting; gently turn the bulb around 30º and

remove it. Follow the process in reverse order to refit.

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03_34

Rear optical unit (03_34)

Remove screw « A» to remove the rear headlight assembly.

Access to taillight bulbs, stop light bulb and license plate bulb.

To reassemble, repeat the operation in the reverse order.

N.B.

IF MISTING IS NOTICED ON THE INSIDE OF THE HEADLAMP GLASS, THIS

DOES NOT INDICATE A FAULT AND IS RELATED TO THE HUMIDITY AND/ORTO LOW TEMPERATURES.

THE PHENOMENON SHOULD QUICKLY DISAPPEAR WHEN THE LIGHT ISSWITCHED ON.

THE PRESENCE OF DROPS OF WATER, ON THE OTHER HAND, COULD INDI-

CATE THAT WATER IS INFILTRATING. CONTACT THE PIAGGIO AFTER-SALES

SERVICE NETWORK.

03_35

Rear turn indicators (03_35)

To gain access to the turn indicator bulbs, remove the fastening screws «E».

The bulbs have a bayonet coupling, to remove them press gently and twist anticlock-

wise about 30°. To refit follow the same steps but in reverse order.

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Rear-view mirrors

Adjust the mirrors by applying slight pressure to the side of the mirror to move it to the

desired position.

03_36

03_37

Front and rear disc brake (03_36, 03_37)

The brake disc and pad wear is automatically compensated, therefore it has no effect

on the functioning of the front and rear brakes. For this reason it is not necessary to

adjust the brakes. An excessively elastic brake lever stroke may indicate the presenceof air in the braking circuit or a failure in the braking system. In this case, mainly due

to the importance of brakes to guarantee safe riding conditions, the vehicle should betaken to an Author ised Serv ice Centre or Dealer .

CAUTION

THE BRAKING ACTION SHOULD BEGIN AFTER ABOUT 1/3 OF THE BRAKE

LEVER STROKE.

CAUTION

HAVE THE BRAKE PADS CHECKED BY THE DEALER ACCORDING TO THE

CHECKS SPECIFIED IN THE SCHEDULED MAINTENANCE TABLE. HOWEVER,IN THE EVENT OF NOISES COMING FROM THE FRONT AND/OR REAR BRAKE

SYSTEM DURING OPERATION, IT IS ADVISABLE TO HAVE THE BRAKE SYS-

TEM CHECKED BY A PIAGGIO DEALER OR AUTHORISED SERVICE CENTRE. AFTER REPLACING THE BRAKE PADS, DO NOT USE THE SCOOTER BEFORE

HAVING USED THE BRAKE LEVER SEVERAL TIMES IN ORDER TO ALLOW THE

PISTONS TO SETTLE AND THE LEVER STROKE TO BE SET TO THE CORRECT

POSITION.

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CAUTION

THE PRESENCE OF SAND, MUD, SNOW MIXED WITH SALT, ETC. ON THEROAD, CAN DRASTICALLY REDUCE THE DURATION OF THE BRAKE PADS. IN

ORDER TO AVOID THIS, WE RECOMMEND WASHING THE VEHICLE FRE-

QUENTLY WHEN RIDING IN THESE ROAD CONDITIONS.

03_38

Puncture (03_38)

The vehicle is equipped with Tubeless tyres (without inner tube). In the event of a

puncture, contrary to the situation with a tyre with inner tube, the tyre deflates more

slowly, resulting in a greater steering safety. In the event of a puncture, it is admissibleto make an emergency repair using an "inflate and repair" spray can. For a final repair,

take your vehicle to an Author ised Serv ice Centre or Dealer. The replacement of a

tyre involves removing the wheel in question. Take your vehicle to an Authorised

Service Centre or Dealer for these operations.

CAUTION

TO USE THE "INFLATE AND REPAIR" SPRAY PROPERLY FOLLOW THE IN-

STRUCTIONS ON THE PACKAGING.

WARNING

THE WHEELS FITTED WITH TYRES SHOULD ALWAYS BE BALANCED. RIDING

THE VEHICLE WITH VERY LOW TYRE PRESSURE OR WITH INCORRECTLY

BALANCED TYRES CAN LEAD TO DANGEROUS STEERING VIBRATIONS.

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03_39

Periods of inactivity (03_39)

We recommend carrying out the following operations:

1. Clean the scooter thoroughly and then cover it with a canvas;

2. With the engine off and the piston in the bottom dead centre position, remove the

spark plug, and pour into its hole 1 t0 2 cc of the recommended oil. Operate the starter button 1-2 times for roughly 1 second to turn the engine over slowly, then insert the

spark plug again;

3. Ensure that the fuel tank is at least half full (in order to ensure the total im-

mersion of the fuel pump); spread antirust grease on the unpainted metal parts;

keep the wheels lifted above the ground by resting the chassis on two wooden wedges;

4. As regards the battery, follow the instructions in the "Battery" section.


AGIP CITY HI TEC 4T

Oil to lubricate flexible transmissions (throttle control)

Oil for 4-stroke engines

03_40

Cleaning the vehicle (03_40)

Use a low pressure water jet in order to soften the dirt and mud deposited on painted

surfaces. Once softened, mud and dirt must be removed with a soft sponge for body-

work soaked with water and shampoo (2-4% of shampoo in water). Then rinseabundantly with water, and dry with a shammy cloth. Any polishing with silicon waxmust always be preceded by washing

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WARNING

IF THE SCOOTER IS USED ON DUSTY ROADS IT IS NECESSARY TO SERVICETHE TRANSMISSION COVER FILTER SPONGE MORE FREQUENTLY.

CAUTION

DETERGENTS CAN POLLUTE WATER. THE VEHICLE MUST BE WASHED AT A

WASH STATION EQUIPPED WITH A SPECIAL WATER PURIFICATION SYSTEM.

WARNING

THE USE OF A HIGH-PRESSURE WATER JET IS STRONGLY DISCOURAGED

FOR ANY ENGINE CLEANING OPERATION; HOWEVER, IF NO OTHER MEANS

ARE AVAILAB LE, IT IS THEN NECESSARY TO:

• ONLY USE FAN SPRAY JETS.

• DO NOT PLACE THE WATER JET NOZZLE CLOSER THAN 60 CM.

• DO NOT USE WATER AT TEMPERATURES OVER 40°C.

• DO NOT USE HIGH-PRESSURE WATER JETS.

• DO NOT STEAM WASH.

• DO NOT DIRECT THE JET STRAIGHT TO THE WIRING AND SLOT DIFFUSERON THE TRANSMISSION COVER.

WARNING

NEVER WASH THE SCOOTER IN DIRECT SUNLIGHT, ESPECIALLY DURING

SUMMER WHEN THE BODYWORK IS STILL HOT, AS THE SHAMPOO CAN DAM-

AGE THE PAINTWORK IF IT DRIES BEFORE BEING RINSED OFF. NEVER USE

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CLOTHS SOAKED IN PETROL, DIESEL OIL OR KEROSENE FOR CLEANINGTHE PAINTED OR PLASTIC SURFACES SO AS NOT TO DAMAGE THE LUSTRE

FINISH OR ALTER THE MECHANICAL PROPERTIES.

STARTING FAILURE

Emergency switch in «OFF» Set the switch back to «ON»

Fuse blown Replace the blown fuse and have

the vehicle checked by an

Author ised Serv ice Centr e.

IGNITION PROBLEM

Faulty spark plug Contact an Author ised Serv iceCentre.

Faulty ignition / injection control

unit.

Contact an Author ised Serv ice

Centre.

Faulty coil. Due to the presence of high voltage, this check should

only be carried out by an expert.

Contact an Author ised Serv iceCentre.

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LACK OF COMPRESSION

Loose spark plug. Screw in the spark plug tightly

Cylinder head loose, piston gas

rings worn.

Contact an Author ised Service

Centre.

Valve stuck Contact an Author ised Service

Centre.

HIGH CONSUMPTION AND LOW PERFORMANCE

Air filter blocked or dirty. Clean with water and shampoo and

impregnate with petrol and specificoil (section «Removing the air

filter»)

INSUFFICIENT BRAKING

Greasy disc. Worn pads. Faulty

braking system. Presence of air in

the front and rear brake circuit.

Contact an Author ised Service

Centre.

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INEFFICIENT SUSPENSIONS

Shock absorber fault, oil leak, end

buffer damaged; shock absorber

preloading incorrectly set


Centre.

IRREGULAR AUTOMATIC TRANSMISSION

Variator rollers and/or driving belt

damaged


Centre.

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Vespa GTS

250

Chap. 04Technical data

71


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TECHNICAL DATA

Engine Single-cylinder, four-stroke

Bore x stroke 72 x 60 mm

Cubic capacity 244.29 cm³

Compression ratio 10.5 - 11.5 : 1

Ignition advance (before TDC) variable (integrated into the ignition

system)

Spark plug CHAMPION RG 4 PHP

Max. speed 120 km/h

Valve clearance intake: 0.10 mm

discharge: 0.15 mm

Overall width 755 mm

Overall length 1930 mm

Wheelbase 1370 mm

Overall height 1170 mm

Fuel supply throttle valve dia. 32 mm and single

injector

Exhaust muffler absorption-type exhaust muffler with catalytic converter.

Electronic ignition inductive, high efficiency

integrated with the injection

system, with variable timing andseparate HV coil.

72

4 T e c h n i c a l d a t a


73/509

Lubrication Engine lubrication with lobe pump

(inside crankcase) controlled by achain with double filter: mesh and

paper.

Cooling Forced fluid circulation, with

engine driven pump; 3-way

thermostat to pump intake.

Transmission Automatic expandable pulleyvariator with torque server, V belt,

automatic centrifugal dry clutch,

gear reduction unit andtransmission compartment with

forced air circulation cooling.

Front brake Ø 220 disc brake with hydraulic

control activated by handlebar right

lever.

Rear brake disc brake, diameter 220 mm, withhydraulic servo operated from the

handlebar with the left-hand lever.

Front wheel Alloy rims: 12" x 3.00"

Rear wheel Alloy rims: 12" x 3.00"

Front tyre 120/70-12", without inner tube

Rear tyre Without air chamber:130/70-12"

Front suspension Single arm suspension (cantilever

wheel) fitted with a dual-chamber hydraulic shock absorber with

coaxial spring.

Rear suspension single arm with two double-acting

hydraulic shock absorbers and

preloading adjustment in 4positions.

73

4 T e c h ni c al d a t a


74/509

Chassis Stamped plate supporting body.

Kerb weight 151 ± 5 kg

Maximum admitted weight ~ 340 kg

Petrol tank ~ 9.2 l (approximate value)

Reserve 2÷2.5 l (approximate value)

Engine oil Capacity: 1.3 l (dry) ; 1.2 l (when

changing oil and filter)

Rear hub oil Capacity approximately 250 cc

Cooling system Capacity: ~ 2.100 ÷ 2.150 l

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04_01

75

4 T e c h ni c al d a t a


76/509

Kit equipment

One box-spanner for spark plugs; one twin screwdriver; one special spanner for ad-

justing the rear shock absorber. The tools are arranged in the front case.

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Vespa GTS

250

Chap. 05

Spare parts andaccessories

77


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05_01

Warnings (05_01)

WARNING

TO PREVENT ACCIDENTS AND TO GUARANTEE PROPER STABILITY, PER-

FORMANCE AND SAFETY, RIDE THE VEHICLE VERY CAREFULLY WHEN IT ISFITTED WITH ACCESSORIES OR WITH UNUSUAL LOADS.

WARNING

IT IS ALSO RECOMMENDED THAT "ORIGINAL PIAGGIO SPARE PARTS" BE

USED, AS THESE ARE THE ONLY ONES OFFERING YOU THE SAME QUALITY

GUARANTEE AS THOSE INITIALLY FITTED ON THE SCOOTER. THE USE OFNON-ORIGINAL SPARE PARTS RENDERS THE WARRANTY VOID.

WARNING

PIAGGIO MARKETS ITS OWN LINE OF ACCESSORIES THAT ARE RECOG-

NISED AND GUARANTEED FOR USE. IT IS THEREFORE ESSENTIAL, IN ORDERTO CHOOSE AND MOUNT THE ACCESSORIES CORRECTLY, TO CONTACT AN

AUTHORISED DEALER OR SERVICE CENTRE. THE USE OF NON-ORIGINAL

ACCESSORIES MAY AFFECT THE STAB ILITY AND OPERATION OF YOUR VE-HICLE AND REDUCE SAFETY LEVELS WITH POTENTIAL RISKS FOR THE

RIDER.

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WARNING

NEVER RIDE THE SCOOTER EQUIPPED WITH ACCESSORIES (TOP BOX AND/OR WINDSHIELD) AT A SPEED HIGHER THAN 100 km/h.

THE SCOOTER CAN BE RIDDEN AT A HIGHER SPEED WITHOUT THE ACCES-SORIES MENTIONED BEFORE WITHIN THE LIMITS ESTABLISHED BY LAW.

IF THERE SHOULD BE NON-PIAGGIO ACCESSORIES INSTALLED, OR AN AB-NORMAL LOAD, OR IF THE SCOOTER IS NOT IN A GENERALLY GOOD CON-

DITION, OR WHENEVER WEATHER CONDITIONS DEMAND IT, SPEED SHOULD

BE REDUCED FURTHER.

WARNING

BE EXTREMELY CAREFUL WHEN INSTALL ING AND REMOVING THE MECHAN-

ICAL ANTI-THEFT DEVICE ON THE VEHICLE ( U-SHAPED PADLOCK, DISK

BLOCK, ETC.).

MAINLY NEAR THE BRAKE PIPES, TRANSMISSIONS AND/OR ELECTRIC CA-

BLES, AN INCORRECT INSTALLATION OR REMOVAL OF THE ANTI-THEFTDEVICE AS WELL AS LEAVING IT ON BEFORE STARTING THE VEHICLE CAN

SERIOUSLY DAMAGE ITS COMPONENTS, COMPROMISE THE CORRECT

FUNCTIONING OF THE VEHICLE AND USERS' SAFETY.

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Vespa GTS

250

Chap. 06

Programmedmaintenance

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06_01

Scheduled maintenance table (06_01)

Adequate maintenance is fundamental to ensuring long-lasting, optimum operationand performance of your vehicle.

To this end, a series of checks and maintenance operations (at the owner's expense)have been suggested, which are included in the summary table on the following page.

Any minor faults should be reported without delay to an Author ised Serv ice Centr e

or Dealer without waiting until the next scheduled service to solve it.

All scheduled maintenance services must be carried out at the specified intervals,

even if the stated mileage has not yet been reached. Punctual scooter servicing isessential to ensure your warranty remains valid. For any further information concern-

ing Warranty procedures and "Scheduled Maintenance", please refer to the "Warranty

Booklet".

SCHEDULED MAINTENANCE TABLE

km x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60

Safety locks I I I I I

Spark plug R R R R R R

Driving belt R R R R

Throttle control A A A A A A A

Air filter C C C C C C

Belt compartment air filter I I I I I I

Oil filter R R R R R R R

Valve clearance A A A

Electrical system and battery I I I I I I I

Brake fluid * I I I I I I I

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km x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60

Coolant * I I I I I I I

Engine oil R I R I R I R I R I R I R

Hub oil R I R I R I R

Brake pads I I I I I I I I I I I I I

Sliding blocks / variable speed rollers R R R R R R

Tyre pressure and wear I I I I I I I

Vehicle road test I I I I I I I

Suspensions I I I I I I

Steering A A A A A A A

I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.

C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE

* Replace every 2 years

RECOMMENDED PRODUCTS TABLE

Product Description Specifications

AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds therequirements of API GL3 specifications

AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions (throttle

control)

Oil for 4-stroke engines

AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased

adhesiveness

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Product Description Specifications

AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-based spray

grease with NLGI 2; ISO-L-XBCIB2

AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MASynthetic oil

AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid

AGIP PERMANENT SPEZIAL coolant Monoethylene glycol-based antifreeze fluid,

CUNA NC 956-16

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TABLE OF CONTENTS

A Air filter: 47

BBattery: 51, 52

Brake: 50, 63

CClock: 10

DDisc brake: 63

Display: 10

EEngine oil: 40, 41

Engine stop: 14

FFuel: 20

Fuses: 54

HHeadlight: 61

Horn: 13

Hub oil: 43

IIdentification: 21

Immobilizer: 14, 18

Instrument panel: 8

KKey switch: 11

Keys: 15

LLight switch: 13

MMaintenance: 39, 81, 82

Mirrors: 63

SSaddle: 21

Scheduled maintenance: 82

Shock absorbers: 30

Spark plug: 46

Stand: 34

Start-up: 14

TTank: 20

Technical Data: 71

Top box: 22

Transmission: 34

Turn indicators: 62

Tyre pressure: 29

Tyres: 45

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The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manualremain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any

changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or con-

struction reasons.Not all versions/models shown in this publication are available in all countries. The availability of single versions should be checked at the official Piaggio sales network.

"© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After-Sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)


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WORKSHOP MANUAL

633577

Vespa GTS 250 I.E.


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WORKSHOP

MANUAL

Vespa GTS 250 I.E.

The descriptions and illustrations given in this publication are not binding. While the basic specificationsas described and illustrated in this booklet remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes tocomponents, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.Not all versions shown in this publication are available in all Countries. The availability of single versions

should be checked at the official Piaggio sales network."© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication

in whole or in part is prohibited."PIAGGIO & C. S.p.A. - After-Sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)


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WORKSHOP MANUALVespa GTS 250 I.E.

This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have abasic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any importantchanges made to the vehicles or to specific fixing operations will be promptly reported by updates to thismanual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools areunavailable. It is therefore advisable to read the sections of this manual relating to specific tools, alongwith the specific tool catalogue.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personalinjury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicleto prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of seriousdamage to the vehicle and sometimes even the invalidity of the guarantee.


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INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

M AINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

INJECTION INJEC

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME


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INDEX OF TOPICS

CHARACTERISTICS CHAR


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This section describes the general specifications of the vehicle.

Rules

This section describes general safety rules for any maintenance operations performed on the scooter.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well

ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust

fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is

highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water

and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks

or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working

area, and avoid open flames or sparks.

- Clean the brake pads in a well ventilated area, directing the jet of compressed air in such a way that

you do not breathe in the dust produced by the wear of the friction material. Even though the latter

contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or

non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon reassembly.

- After removal, clean the components using non-flammable or low flash-point solvent. Lubricate all the

work surfaces except the tapered couplings before refitting.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and

screws are not interchangeable with coupling members with English measurement. Using unsuitable

coupling members and tools may damage the scooter.

- When carrying out maintenance operations on the scooter that involve the electrical system, make

sure the electrical connections have been made properly, particularly the ground and battery connec-

tions.

Characteristics Vespa GTS 250 I.E.

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Vehicle identif ication

Chassis prefix: ZAPM45100000 ÷ 1001

Engine prefix: M451M ÷ 1001

Dimensions and mass

DIMENSIONS AND MASS

Specification Desc./Quantity

Total loadless weight 151 ± 5 kg

Width (to hand grips) 755 mm

Length 1930 mm

Wheel base 1370 mm

Saddle height 800 mm

Vespa GTS 250 I.E. Characteristics

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Fuses 1: 30A - 1: 15A - 3: 10A - 4: 7,5A - 1: 3A

Generator alternating current

Frame and suspensions

FRAME AND SUSPENSIONS


Type Unitised body made of stamped plate

Front suspension Single arm suspension (cantilever wheel) fittedwith a double-acting hydraulic shock absorber with

coaxial spring

Front shock absorber axial travel 86.5 mm

Rear suspension Engine with swinging fork attached to frame bymeans of an arm with 2 degrees of freedom Pair

of double-acting hydraulic shock absorbers andcoaxial springs with preloading adjustment in 4positions.

Rear shock absorber axial travel 89.5 mm

Brakes

BRAKES


Front Ø 220 disc brake and floating calliper with Ø 25mm twin plungers and hydraulic control (lever on

the far right end of the handlebar)Rear Ø 220 disc brake and calliper with two Ø 30 mm

counteracting plungers and hydraulic control (lev-er on the far left end of the handlebar)

Wheels and tyres

WHEELS AND TYRES


Front wheels - light alloy rims 3.00x12

Rear wheels - light alloy rims 3.00x12

Front tyres 120/70-12" Tubeless

Rear tyres 130/70-12" Tubeless

TYRE PRESSURE


Front tyre pressure (when cold) 1.8 bar

Rear tyre pressure (when cold) 2 bar

Tyre pressure (when cold) with passenger 2.2 bar

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU-LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES

Vespa GTS 250 I.E. Characteristics

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Tightening Torques

GRUPPO STERZO

Name Torque in Nm

Upper steering ring nut 35 ÷ 40

Lower steering ring nut 12 - 14

Handlebar fixing screw 45 ÷ 50 (The two screws must be tightened to theprescribed torque after having done so with the

rear wheel axle nut. Safety locks: see «Pre-deliv-ery Operations» )

Fixing screws for handlebar control assembly U-bolts

7 ÷ 10

FRAME ASSEMBLY

Name Torque in Nm

Engine-swinging arm bolt 64 - 72swinging arm bolt - body shell 76 ÷ 83

Engine and vehicle side swinging arm junction bolt 33 ÷ 41

Bolt of the Silent block support plate 42 ÷ 52

Centre stand bolt 32 ÷ 40

Side stand fixing bolt 35 ÷ 40

SOSPENSIONE ANTERIORE

Name Torque in Nm

Screw fixing the shock absorber to the shock ab-sorber - calliper attachment plate

20 ÷ 27

Wheel axle nut 74 ÷ 88

Wheel screw 20 ÷ 25Screw fixing rear mudguard to steering 5 ÷ 6.5

shock absorber upper clamp 20 ÷ 30

FRENO ANTERIORE

Name Torque in Nm

Brake fluid pump - hose fitting 20 ÷ 25

Brake fluid tube- calliper fitting 19 ÷ 24

Vite serraggio pinza alla piastra attacco ammor-tizzatore - pinza freno

24 ÷ 27

Disc tightening screw 6 (Apply LOCTITE 242 threadlock, mediumstrength)

Oil bleed screw 12 - 16Pad fastening pin 19.6 ÷ 24.5

Viti vaschetta pompa freno 1,5 ÷ 2

REAR SUSPENSION

Name Torque in Nm

Retainer for left shock absorber to crankcase sup-port plate

20 ÷ 25

Shock absorber upper fitting 20 ÷ 25

Shock absorber lower fitting 33 ÷ 41

Rear wheel shaft 104 ÷ 126

Screw fixing wheel to hub 20 ÷ 25

Screws for muffler - shock absorber support armon engine

20 ÷ 25 (The two screws must be tightened to theprescribed torque after having done so with the

Characteristics Vespa GTS 250 I.E.

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Name Torque in Nm

rear wheel axle nut. Safety locks: see «Pre-deliv-ery Operations» )

FRENO POSTERIORE

Name Torque in Nm

Brake fluid pump - hose fitting 20 ÷ 25

Brake fluid pipe-calliper fitting 20 ÷ 25

Rear disc tightening bolt 11 ÷ 13

Oil bleed screw 12÷16

Calliper to engine tightening screw 20 ÷ 25

Viti vaschetta pompa freno 1,5 ÷ 2

Vite accoppiamento pinza 30 ÷ 33 Nm

MUFFLER

Name Torque in Nm

Muffler heat guard fixing screw 4 ÷ 5Screw for fixing muffler to the support arm 20 ÷ 25

Lambda probe clamp on exhaust manifold 40 ÷ 50

Exhaust manifold-muffler joint clamp 12 ÷ 13

Manifold - muffler diaphragm tightening clamp 16 ÷ 18

LUBRICATION

Name Torque in Nm

Hub oil drainage plug 15 ÷ 17

Oil filter on crankcase fitting 27 ÷ 33

Engine oil drainage plug/mesh filter 24 ÷ 30

Oil filter 4 ÷ 6

Oil pump cover screws 7 ÷ 9Screws fixing oil pump to the crankcase 5 - 6

Oil pump control crown screw 10 ÷ 14

Oil pump cover plate screws 4 ÷ 6

Oil sump screws 10 ÷ 14

Minimum oil pressure sensor 12 ÷ 14

CYLINDER HEAD

Name Torque in Nm

Spark plug 12 ÷ 14

Head cover screws 6 ÷ 7

Nuts fixing head to cylinder 7±1 + 10±1 + 270°Head fixing side screws 11 ÷ 12 Nm

Starter ground screw 7 ÷ 8.5

Tappet set screw lock nut 6 ÷ 8

Inlet manifold screws 11 ÷ 13

Tim

vespa gts 250 service manual

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